Improving CRF by 35.6% at a textile manufacturing plant, using EverSense for Condensate Recovery Factor

Condensate recovery factor (CRF) was low, at approx. 37% Inefficiencies across the steam and condensate network, impacting overall thermal efficiency.

Steam leakage from a Soft Flow equipment and bypass steam from one of the U-Jet machines led to direct energy loss.

Equipment such as Calendar, Compactor, and Zero Zero were draining 3–4 TPD (tones per day) of condensate.

Improper condensate return design created backpressure, restricting condensate flow and impacting pump performance.

An FJP’s overflow temperature drops indicated motive pressure inconsistencies, requiring adjustment to 5.5 barg and consideration of a new PRV.

To improve and sustain their utility KPIs using EverSense for CRF, a Forbes Marshall Digital solution. The goal being to steadily improve CRF to 60%, reducing overall fuel consumption and to increase feedwater temperature to 85°C (185°F). Once achieved, sustenance is key.

Our plant layout mapping enabled targeted monitoring and diagnostics.

Uptime monitoring of key equipment enabled through EverSense identified performance gaps and leak points.

Detailed observation of the Steam & Condensate Network across Calendar, Compactor, Zero Zero, and others enabled machine-specific loss identification.

Minor steam leakage resolved in the Soft Flow machine and Bypass steam loss identified and rectified for a U-Jet machine.

Non-CRF Drain Detected & Mitigation Initiated: Backpressure issue identified, and PPPPU pump suggested and installed.

Feedwater System Optimisation Initiated: FJP overflow temperature issue resolved by increasing motive pressure to 5.5 barg.

PRV installation proposed and completed, stabilising and maintaining desired pressure levels.

Increased CRF from 34–39% to 42–57%, moving toward the benchmark (60% goal).

Improved motive pressure to 5.5 barg which improved feedwater tank conditions.

Improved feedwater tank temperature from 65-75°C (i.e.149-167°F), moving toward the benchmark 85°C (185°F )

Reduced steam losses by fixing leakages and bypass steam issues.